CA2069474A1

CA2069474A1 - Vandal-resistant seat

Info

Publication number: CA2069474A1
Application number: CA002069474A
Authority: CA
Inventors: John Arthur Clements
Original assignee: Individual
Current assignee: Hendersons Industries Pty Ltd
Priority date: 1989-12-11
Filing date: 1990-12-10
Publication date: 1991-06-12
Also published as: NO300259B1; US5275769A; AU6958891A; NO921963L; DE69027687T2; GR3021008T3; EP0593448A4; ATE139928T1; KR920703295A; WO1991008886A1; EP0593448B1; NO921963D0; EP0593448A1; DE69027687D1; AU639972B2; ES2090298T3

Abstract

A method of manufacturing a formed article is disclosed which includes an outer fabric material and an inner micro-cellular thermosetting foam plastics material, comprising placing the outer fabric material, which has been treated on its inner side with a flexible thermosetting plastics material composition, in a mould;
closing the mould to define a mould cavity and to deform the fabric material to a predetermined configuration; injecting a foamable flexible thermosetting plastics material composition into said mould; allowing the foamable flexible plastics material to react and completely fill said mould, the pressure of the reaction in the closed space of the mould causing the flexible plastics material to bond to the fabric material; allowing the resultant fabric covered micro-cellular foam plastics material to cure; opening the mould and removing the article.

Description

r~ U ~ V ~ ~
W091/08886 PCTtAU90/0058~ !
~" ;~ iii," ,;",, '~
-- 1 -- t VANDAL-RES _TANT SEAT
The present invention relates to methods of manufacturing laminated articles, in particular to laminated articles that are used as a seat cushion or a seat back support, and more particularly to vandal or damage resistant seats for use on public transport.
A number of vandal resistant seats offered for use in public transport in recent years have been criticised because they are too hard and lack comfort, for example the seat described in Australian Patent Application No.. 52495/86 .
uses a polyurethane (V8080) and Moca. Supplied by Uniroyal .
Aust. Pty. Ltd. this provides a high tensile elastomer with a shore "A" hardness of about 75-85 which is used in conjunction with a wi.re mesh with a wire diameter .75mm.
15 The wire in this construction presents.a reasonably stifE . ¦
form without the elastomer. The addition of.the elastomer makes a very.stiff and board like seat. The elastomer is hard when moulded into a seat without the wire ' reinforcement. While~mesh of a chain-mail type is mention .
it would do little to improve the flexibility in this case unless a softer more flexible elastomer were to be u~ed.
Moreover, this process uses a material that needs to be kept at elevated temperatures, i.e. in excess of 100C and ................ '.
requires a long curing period, for example 2 hours,plus.post curing ~or a further 8 hours.~.Vickers-Xatal AU-B-12028/88 :describes a solid form.seat,pan covered by a flat sheet which illustrates the,difficulty experienced.by;others ..~..atte~pting to:mould vandal resistant materials into seat.
:...,shapes.and.retain the flexibility necessary for some,degree 30 of comfort.,.,The:method of moulding seat ~hapes,appears~.to .
have.been abandoned:in favour;of,a solid..seat pan. . ,..~ '' n.~ .U.K....... Patent-G.B.~204,107,420 to J.~L... ,Danton and M.
. Duret~,~ialso:teaches a wire reinforced construction,.while this,produces a softer and mo,re lexible ~eat it has;other ma~ufacturing..limitati,ons.in.,tpat~only.flat sheets.appear to '.1'it be~produced by..this metho,d,.j-~-J.L.~panton,and,M..~.Duret,in -European P.at,ent No..~0,201,419; FIGS.~1-8j~,descr,ibe ~a..method by ~which a~three dimensional~eat.~shepe as opposei to a ilat .. , ' 1.

' ~

2~ 7~ ~

sheet may be made. This is done by fixing or moulding the previously manufactured sheet into a rigid plastic or metal frame. Unfortunately a flat sheet fixed in this manner tends to become stiffer unless it can elongate and flex -which of course this material cannot. A somewhat hard and uncomfortable seat material results.
Other methods published on the manufacture of vandal or damage resistant seats e.g. U.S. Patent No.

3,647,608, D. S. Enlow describes a method for producing a softer seat. ~owever it has been found that seats manufactured by this method provide little resistance to damage by puncturing, and are not difficult to slash because the article is made of a foam in the density range that would normally be used for seating i.e. 35-60Kg. per cubic meter, and reinforced by unconnected randomly oriented wires or metal fibres. Foams of this type have relatively low tensile strength and when used in combination with unconnected wires are not-difficult to hack and pull apart, therefore seats manufactured by this method present only ' limited resistance to attack by vandals. D. S. Enlow in this invention did not consider damage that may be caused by - fire from either large or small ignition sources. The~
overall resistance of articles made by this method are therefore-limited.~
The current favoured method of`manufacturing a vandal resistant seat involves producing a wire reinforced microcellular urethane elastomer:seat form, mounted on a board and supported on a fire retardant foam. The seat:form thën has to be'covered by a-woollen fabric which is at'tached ;to the seati;form in'à manneritha't makes~the fabric a~ "'!
difficult'as possible to remove'or damage.'!iThe fabric is trëated;with'at~least`;three heàvy'coats'of:'adhesive. The 'sea't'~fo'`rm:'is''"al`so'`'trea'tèd 'with'adhesive,'iand the adhesive is :`allowe~ to'dry''.~ The'seat form~'and the' adhesive coated-~' wool~len'':fabric''are th`e`n p'laced in an infra' red oven'`and i heate'd~until;tacky'''to~reactivate~'the'adhesivé.'~The woollen fabric is~'-the'n~!'p`làced onto the séat form1taking'carelto'-' align the pat`ter'n 'and'''r'emove''cre~'ses.~~''The form'-is tri~med .

WO 91/08886 ~ f~ PCI/AO90/00585 :, `, ,"
-- 3.--by pulling the woollen fabric around the corners and sides of the seat form and stapling onto the boarcl. The operation of placing the treated woolen fabric on the seat form and trimming the part is very time consuming ancl requires a high degree of skill. As will be appreciated, mistakes made during this operation result in very expensi.ve scrap.
The prior art methods that are specific to the manufacture of vandal-resistant seats theref.ore have a number of limitations. -It is an object of the present invention to.
alleviate at least some of the aforementioned disadvantages. ,' . In accordance with the foregoing and in one aspect of the present invention there is provided a method of.
manufacturing a formed (vandal resistant) article including an outer fabric material and an inner micro-cellular ' '.
thermosetting foam plastics material, comprising : ..
placing the outer fabric material, which has been treated on.its.inner side with a flexible thermosetting plastics material composition, in a mould;
closing the mould to define a mould cavity and to deform the fabric material to a predetermined'configuration;
injecting a.foamable flexible thermosetting plastics material comp'osition into:said mould;
.i allowing lhe:;foamable flexible:plastics:material to react and completely fill said mouldj.the pressure~of.the reaction in the closed space of the mould causing the flexible plastics material to bond-to.the fabric.material;
. 'allowing.the resultant fabric covered micro-cellular ~oam plastics.'materialito:.cure;
opening.the;mould.i.,and removing~the.. article..... :.
;,The formed articl'e'may-in~a~preferred aspect include a wire~mefchireinfo'rcing-,and thus:in a 6ec'0nd~aspect thei:invention provides a.method off;manufacturingra formed wire mesh-:rein~orced:'article~including'an outerifabric .
material and~an/inner.micro-cellular ~oam thermosetting ~
comprising~plastics.materialireinforced~by a-imetal-;wire m'esh embedded therein comprisiny~placing~theiouter-lfabric.
material, treated on its inner side with a flexible thermosetting plastics material composition in a mould;

WO91/08886 ~ O~ PCT/AU90/00585 closing the mould to deform the fabric material to a predetermined configuration;
opening the mould and inserting the wire mesh on ' the inner side of the fabric;
closing the mould and injecting a foamable flexible thermosetting plastics material composition;
allowing the foamable flexible plastics material to react and completely fill the mould, the pressure o the reaction in the closed space of the mould causing the 10 flexible plastics material to surround the:wire mesh and to . ', bond to the fabric material;
. allowing the resultant fabric covered reinforced micro-cellular foam plastics material to cure;.
. opening the mould and removing the article.
The invention may also provide in a furtner aspect a method of manufacturing a formed article comprislng :
. . placing a preform having an outer fabric material, treated on its inner side with a flexible thermosetting plastics material`composition, in a mould;
! injecting a foamable flexible thermosetting plastics material composition into said mould; : , allowing the foamable flexible plastics material to react and completely.fill said.mould, the process of the~
~.reaction.:in:the.~closed~s~paceiof~the_mould causing the flexible plastics material to bond to the fabric material;
...: allowing-the.,resultant.fabric covered ...
micro-cellular,foam plastics material to cure;s , :
opening the.mould and.,removing..the.article.
The fabric material,.of:the,preform may~also include on its,inner~sside:,a wire,~mesh:relnforcing..~ "3 ~ 7~ The~.invention.also'relat'es.,to articles!manufactured Jin.accordance,with the method..of,manufacture.i !:. . ,~i ~.. ~'!.:
;j !,lr,-,.^ .~The~flexible..~thermosetting plastics material.;is :
selected~for~compa~ibility~with:the foamable-splastics ~
material~sso,,that maximum b~nd:strength3be.tween~the outer,,is . .
- eefabric.-material andlthe:iinner, preferably~wire~reinforeedi foalllable~plastic5~lmat~!!rial i~is:~af-~hieved~ '3~ J~ ? .
~ r ,~ 3 ~ t .;~7~ r,~ ~ :.?. '! -:?.'7~f ~ ~`, I-r'~

WO9l/08886 2 0 6 9 ~ ;7~r ~ PCT/AV90/00585 ,~" _ 5 In one preferred aspect the fabric material and wire mesh are placed in the mould with the mould in a horizontal plane. When closed, the mould is tilted to a vertical plane, and the foamable plastics material is injected into the top of the mould and flows down through the mould under the influence of gravity.
The mould is so'constructed as to allow the - -injected foamable plastics material to push the air in the mould down through the mould and vent out of the bottom of the mould. The gel`or setting time of the foamable plastics - material is timed to gel or set as it enters the vents.at the bottom of the mould. Filling of the mould continues until the foamable plastics material overflows via a vent into channels provided for this purpose. Filling continue's until all settling in the channel stops.
,The product is allowed to cure then removed from the mould. ;. . . ..
In an alternative process which produces a more resilient and "softer feel",product the amount of foamable flexible plastics material injected into the mould is' preferably f'rom 50% to 100% by volume of the unexpanded or -: unfoamed flexible plastics material as compared to the, total volume of the mould with from 60% to.99% v/v being preferred and from 75% to 95%~v.iv. being.particularly,preferr,ed.~,The reaction of the foamable flexible plastics ma,t~erial', in th~e confined space (o'f up:to 50% of the volume of the foamable'~
:~'fI~exible plastics material,volume if it were permitted~to "-foam'and expand.unfettered) produces~the micro-cellular foam plastics material.integrally bonded to the outer fabric.
30By:~moulding;.ther'.foamablei;plastics;material which is ~preferably.~wire~reinforced.directly.Lonto,.the.~woollen,fabric, thereby forming the fabric material to~a predetermined~f~$
: '"''~'`'shape', the ne~ed.,for;iskill.~is~:greatly reduced,.jand the time rèquired~to)produce~a':seatl~cushion-orsseat back.,is reduced '~. 35 by approximately315ito--20 minutesLper.-,part.. ~Thus,,the .~
method`~:'of.'the: invention-provides.i':improved.:production metho'd's 'j~and'a~;reductio'n.in...the time.:?.taken...to produce.~.an:,article..
r ~ t ~ i ! 5, `~? ~ 3 ~ e, 2 ' - ~t ~'~ ,t, , ,~,' , wo 9l/n88x6 2 0 6 9 ~ 7 ~ Pcr//~u90/l)0s8s ~ ne feature of the invention is the high bond strength of the (preferably woollen) fabric ~aterial to the foamable plastics material. This is achieved by the application of a urethane adhesive to the Eabric. An example of a suitable adhesive is No. ?518 plus isocyanate No. 2518/7. Available from Beta Chemicals Melbourne Victoria, or Daltobond VF/AR available from I.C.I.
Adhesives. High bond strengths are achieve~d by the application of heavy coats of adhesive by spraying. Three heavy coats are generally required. The adhesive is applied so as to penetrate to about 50% and not less than 30% of the depth of the fabrics fibres so as to bond the fabric material into one-continuous sheet. In this manner maximum mechanical bonding is obtained. The isocyanate will also react with moisture present in the fabrics fibres thereby improving the bond. Fabrics back coated in this manner show a marked improvement in resistance to wear by a~rasion. The preferred fabrics of the present invention, predominantly selected for aesthetic reasons, are moquette type ~abrics and denser woven woollen fabrics.
In an alternate embodiment, the preformed fabric is transferred to a second mould where wire is inserted~(on the inner side of the fabric). The mould is closed and a : oamable plastics material composition is:injected to 25- completely fill-the mould. : -~ :~ 'By allowing the foamable plastics material to~react, the pressure of the reaction in the closed~space of ~the~mould causes the flexible plastics material to surround the wire mesh and to bond to the fabric material. ! : .:
' '!'! L~' The~resultant:fabric covered reinforced microcellular foam~plastics:materialrislallowed;to curelin thé~normal manner.~ !af.~J~ J 1u -fi Df-., '1 " ,-,~, I~-t `'!~3~ ' ~?f~ Therwire mesh:may~be:an ordinary fly-wire type= mesh ~orf~a!"cyclone fence"~type1mesh,-which~is favoured.as.itT;
providesl/better-.flexibility.in the~finished!article.; s ,J:r ~ ~ f;~ The~foàmableiplastics material ~fiS preferably aj?~
poiyurethaneifoam or~a iilicon(e) foam.~ The-~polyurethane foam is preferably a fire retardant polyurethane foam as will be described in greater detail hereinafter.

WO91/08886 2 ~ PCT/AU90/0058~
4 ~ ~ s .. ~,., - 7 -A further aspect contemplated by the present invention is to ensure the maximum level of fire performance possible, i.e. no spread of flame, the ability to withstand-attack from large ignition sources to produce low levels of smoke and toxic gases during combustion, and to provide the maximum time from onset of ignition to the development of smoke in order to allow people to either escape the area of the fire or put out the fire.
, The invention refers to polyurethane materials that can be-used at room temperatures i.e.'preflerably in the range 25-50C. The preferred polyurethane materials of the invention require only short mould resident times i.e. 3-6 minutes from pour to demould. ,The preferred material should require no post curing. The invention refers to a fabric covered preferably wire reinforced microcellular polyurethane seat cover. The seat cover is moulded in one shot,i.e. the.fabric covering material, wire reinforcement if required, and elastomer are moulded and bonded together in the, mould.
As mentioned before, the preferred materials should be highly fire retardant or capable of being made so. The fire retardant properties should include low smoke low toxic products of combustion.
. , " ,,~" . Such,a.,mater,ial..is preferably a polyether.based.., polyurethane derived from a Diol- or a~Triol-based polyol where.at least 50% of the hydroxyl end groups are primary ,end.groups and an,isocyanate. Preferably-a polyurethane , foam including a,fire retardant system of,:a chlorinated paraffin, sodium, tetra-borate, antimony trioxide, and , 30 .~.,alumina.trihydrate. ,Polyols.used in making~.the.present invention are preferably.diols or~.triols",having:a.molecular' weightjof~about.,.,2500-,7500,:and-at.least.50%.oftthe hydroxyl ~end~groups,being primaryihydroxyl.end.groups. ~ Examples of diols;or,t,riols-well suited-to~,*he;present,.invention arei~
line,ar,an.d.l,branched polyoxypropylene:po.lyols~block.~. 't'~
,.,copol,y.me,rs of~,ethylene~,oxide and-propylene.,oxide,-.and.polyol~ -grafts o~,,ethyl,eni,c,ally..unsaturated monomers.suchlas.~in,~
particular styrene and:acrylonitrile on~.,the.:a~orementioned WO91/08886 ?~ )~t?,~ PCT/AU90/00585 1, polyols. These polyols will be substantially free from functional groups other than hydroxyl groups and as mentioned above, will be in the main tipped with primary hydroxyl groups. Most preferred at least abou~ 78% of the hydroxyl groups are prima'ry hydroxyl end ~roups. Examples of suitable polyols available commercially are CP4701. ( Dow Chemicals), Niax 11-34 (Union Carbide), Desmophen 3900 (Bayer), propylan Ml2 ~Lankro Chemicals), and Daltocell T
32-75 (I.C.I.). Examples of suitable grafted polyols or polymer polyols or PHD. polyols (i.e. dispersions of polyvinyl or polyurea compounds in diol or triol polyols) commercially available are Niax 34-28 (Union Carbide), Pluracol 518 (BASF-Wyandotte) and PU 3119 (~ayer). E609 (Union Carbide).
Water is usually added to the blend as a blowing agent in order to create a foam plastics material as it reacts with excess isocyanate to liberate carbon dioxide gas. Most commercial polyols have between 0.05-0.1~ water in them and usually about 0.08~ the water normally present in the polyol is all that is required for minimum blowing.
If a totally non foamin~ elastomer is required it would be necessary to place the polymer in a vacuum oven and heat to about 80-90C for 4-8 hours to remove all air and moisture. As the polymer is confined within the mould and the mould is filled, the pressure of the reaction in the closed space of the mould'allow~ very little foaming to take " place. The microcellular elastomers made according to;'the invention have pèrformed as described-later. A non ceIlular elastomer is not considered to offer any advantage.'-' '7''''" '' The preferred isocyanates are toluene di-isocyanate, ~:~TDIj,polyméthylene,polyphenyl iso~cyanate and' '' ~''''''~
,dipheny}methanc';'di-.isocyanatej both of which:'are kn,own as MDI;-~and.mixtures:of these two;~isocyanates'.~'' The'invënt'ion does not preclude the use~however'of other aromatic and~ !
aliphatic~isocyanates known~in~,the:art. The 'amount-of -' ; isocyanate-required~i-s-regulated-by the stoichiometry of~the reaction;!-an index.of 100-120~ivingimi~crocellular a-~
elasto~ers with optimum-'physical`prope~rti'es'.'~ 5 WO91/08886 ~ ~ 9~7 ~ PCT/AU9OtOO585 The foamable plastics material is preferably a polyurethane foam. The polyurethane is preferably a fire retardant polyurethane foam, including a borax and/or hydrated alumina and antimony trioxide and a chlorinated paraffin. The flame retardant system of the present invention includes about 5-25 parts by weight of antimony trioxide, about 10-60 parts by weight alum:ina trihydrate, about 10-B0 parts by weight of sodium tetraborate, and about 20-80 parts by weight of a chlorinated paraffin, based on 100 parts by weight of the polyol. The antimony trioxide will generally be present in the-formulation in an amount ranging from 5-20 parts by weight, preferably from about 7-I5 and most preferably about 12 parts. The chlorinated paraffin will usually be present in an amount ranging from 25-65 parts by weight, preferably from about 40-60 parts, ' and most preferably 40-50 parts. Alternatively the paraffin can'be expressed'in terms of the chlorine content and generally there is present about 20-40 parts,' preferably about 25-35 parts by weight of chlorine. The term "chlorinated paraffin" includes a single chlorinated para~fin or mixtures thereof.
' Chlorinated paraffins have a chlorine content-ranging from 30%-70%. A chlorinated paraffin with a chlorine content'of about'60~ is preferred. The chlorinated paraffins may be either liquid or solid for example CERERCLOR 70 or 70L. (CERECLOR is a Registered Trade Mark of I.C.I.) the liquid chlorinated paraffin is preferred.
''`Catalysts,' promotors and amines known'in the art a're`used'in the:formulation of foam polyurethane co'mpositi`ons'de''scribed above.' ' - -' Other''elastomers'and foams which mayjbe used in'placeJ'of polyure'thane''elastomersiand polyurethane foam materiàls:are'silicone elastomers!such as'-RTU.627-and-~siliconé'foams RTF'.762'and RTF.8510 produced by General Electr`ic', Silicone'Products'Divi'sion, Waterford,i;New York ~-12188. Thes'e~silicone~-elastomers and~foams have excellent flr'ë'r'etar'dant~p'roperties'.~ Theisilicone'~elastomer/foam 'pro`duc~t's~~ar''e~ made'-:'i'n'~sim'ilar manner'to'the'polyu'rethane elastomer/foam products described earlier.

WO91/08886 , ~ ; PCT/AU90/0058~ ~
2069~74 ~

In one particularly preferred form of the invention, the fabric covered steel mesh reinforced micro-cellular foam when moulded forms a hollow case, the ' lower 10mm. of the outer circumference of which is not covered by the fabric material. The hollow case is then mounted on a 10mm. plywood board by stapling through the lower 10mm. of the hollow case provided for this purpose and into the edge of the plywood board. The plywood board may be made fire retardant by treatment with known fire retardant chemicals,for timber. The'fabric cover which extends about 100mm. past the lower edge of the fabric.
covered wire reinforced hollow case is then pulled over the lower edge of the hollow case and stapled to the underside of the plyboard by two continuous rows of staples. The woollen cover stapled in this manner extends about 25-30mm onto the blyboard base. The excess woolen fabric is then trimmed-off. The staples pass through and around the wire reinforcement to attach the seat ~orm firmly to the plywood board.
By way of example only two foamable plastics material (elastomer) formulations were chosen. The elastomers were chosen so that the tensile strength of the , elastomer referred to as No. l is a little higher than the ; ,~tensile strength of the woollen fabric material and the elastomer referred to as No. 2 is a little below the tensile , strength of the woollen fabric material.
. , : Elastomer No. 1 S~ORE,"A" hardness 45-50.
-~ Elastomer No. 2 SHORE "A" hardness 335-40.
,In order to maintain flexibility, a flexible wire mesh supplied by ~unter WirejProducts,was selected with pitch,as described in,Australian Patent No. 41933. This '~' allowedrfor an, optimum,elastomer thicknessj,of.5-6mm, the intention being to-reduce"the,;hardness and increase.the, flexibility. ,A-further feature of the invention,is,to ~choose materials,:so-as to achieve maximum ~bond strength :,,between the.elastomer;and,the,.woollen fabric.~
',.'fS'.~ j` Test~samples were;producedito;evaluabe,~the peel strength of the-elastomers.,~Test samples!5mm*60mm*240mm, WO91/08886 2 0 6 9 ~ PCT/AU90/005~5 .~.~ `` .

reinforced with wire supplied by Hunters Wire Produ~ts and covered with a pure wool fabric. The samples were ~ubjected to a standard "T" peel test as outlined in attached sheet Q.P.5.
Test samples referred to as elastomer No. 1 SHORE
"A" 45-50 had peel strengths in the range 120-150 Newtons.
Test samples referred to as Elastomer No. 2 SHORE
"A" 35-40 had peel strengths in the range 65-90 Newtons.
A number of the tests on test samples of elastomer No. 1 ended pre~aturely due to the wool fibres pulling apart. This mode of failure is ideal where the wool pulls apart rather than peels away, the elastomer and the bond being stronger than the tensile strength of the fabric~
For the elastomer referred to as No. 2, the samples peeled uniformly behind the joint line, in this case the fabric to elastomer joint line being stronger than the tensile strength of the elastomer.
While it would appear that the harder material sample No. 1 would be most preferable from the vandal resistant point of view, trials conducted so far have indicated that both elastomers have performed equally in test situations, the No. 2 elastomer being preferred for its extra flexibility and softer peel. In this case when the softer material is made into a seat where there are no loose edges ~or the vandal to start a tear, the so~t elasto~er No.
2 is as difficult to start a tear as elastomer No. 1. In order to start a-tear a tri-an~ular cut must first be made and then a corner must be dug or prised up so that a section o~ the fabric cover can be peeled away. In trials this has proved very dificult.
- ~: EXAMPLES OF FORMULATIONS ~ I
EXAMPLE 1. P.s.w.
E.609 ~ 0 0 .
CERECLOR 70L 35.0 SODIUM TETRABORATE ';., 15~0.. ~ ~:s ,~ ' 7 Al.UMINA ~TRIHYDRATE ~ 7.15 . 0 ANTIMONY TRIOXIDE 15 . 0 THORCAT 535 1. 0 ,' ' ' .. ' ' ' , ~ : ' .

WO91/08886 2 ~ ; ' PCT/AU90/00585 ISOC~ANATE VM25 7.2 EXAMPLE 2. P.B.W.
E.609 60.0 CP. 4701 40.0 5 CERECLOR 70L 35.0 SODIUM TETRABORATE 15.0 ALUMINA TRIHYDRATE 15.0 ANTIMONY TRIOXIDE 15.0 THORCAT 535 1.0 10 ISOCYANATE VM25 9.2 EXAMPLE 3.
. P.B.W.
POLYOL E609 60.0 VORANOL 4701 40.0 15 D~.437 21.5.
WAT~R 2.5 CERERCLOR 70L 50.0 Al2O3 - 3H2 ALUMINIUM TRIHYDRATE 15.0 Sb2O3 ANTIMONY TRYOXIDE 10.0 20 Na2~4O7 lOH20 SODIUM TETRABORATE 15.0 ISOCYANATE VM25 @ 105 INDEX 62.5 : -E609 Polymer Polyol - Supplied by Union Carbide.

VORANOL 4701 Polyol - Supplied by Dow Chemicals. :

VR.437 Catalyst Blend -'Supplied by Dow Chemic~

CERERCLOR 70L Chlorinated Parrafin.

VM.2S I~ocyanate~M.D.I. .`. .i-"~T ~
Di-i60cyanato-Diphenylmethane - Supplied by.I.C.I.~ .L
'' ' . i .~ iJ ~, .' t ~. i, ,. i .. . r . ~ ~ ~
.: ~

.. WO 91/08886 2 0 ~ ~ ~ 7 ~ PCT/AU90/0058~ ~

Samples te~ted at AWTA Textile Testing Melbourne with the following results.
Test method Ats 1000.001 Airbus Industry spec. to evaluate toxic gas and smoke emission.
Ats 1000.001 Smoke emission and toxicity Maximum requirement Of nases Duration 90 240 480 secs. 90 secs. 240 secs.

l(a) Non Flaming Test. Minimum Light Tralnsmission (MLT)%
1. 78.5 40.0 0.790 2. 75.0 34.5 1.300 : 3. 66.0 25.8 0.570 4. 60.0 16.8 1.130 l(b) ~pecific Optical Density (DS) 100 200 i. . 14 53 277 . .
2. 16 61 2S0 3. 2~ 78 296 : .
4. 29 106 25g , l(c) Gas Samples ppm.
.20 ::.HF.. ;, , . .: *1.5. ~1.5 .. . I .. ;50 .. 50 HCL. 5 *50 ~A *50 ~ 50 500 HCN. *2 *2 100 150 ~02. *20 *~0 50 100 ' CO. *1000 *1000 3000 3500 2.5 NO ~ NO2 *2 *2 50 100 .
2~a) Flamin~ Test. Minimum ~ight Transmis~ion (M~T) % -.; 1. 33.0 0.25 0.120 2. 78.5 0.27 0.091 , : 3. 57.0 0.60 0.180 30 4. 61.6 0.42 0.095 "

`;

;, ' ' ~' ' ' ~
:
', ,: ' , . :

6 -~ ~J~ PCT/AU90/00585 I
t ~ ' 2(b) Specific Optlcal Density (Ds) 100 200 1. 63 344 386 2. 14 333g 401 3. 32 293 362 4. 28 314 399 , 2(c~ Gas Sampled ppm HF. *5 *5 50 50 HCL. ~50 *50 50 500 HCN. *2 *20 100 150 S02. :: :~' *20 *20 - 50 100 ..
CO. *1000 *1000 3000 3500 NO + NO2. *10 ~10 .50 100 * Les~ Than.

All ~amples ~ere reinforced with wire,mesh and covered with a woollen fabric which had been flame retarded with 8% PFZ.#

# Potas6ium Fluor-Zirconate.

Sample seat6 were tested to CSIRO proto~ol for the asse~ement of fire behavior of furniture u~ing large ignition ~ource6 parts 1&2. 300... 400.:& 600. Gram Cribs .:
were uged on ~ample~ made from formulation~ 1 & 2.

.

,, , , I

:

~' ' ' W091/08886 2069~7~ PCi/~U90/~0585 _ CRIB TEST SUSTAINED SUSTAINED COMBUSTION RESULT
MASS No. FLAMING SMOLDERING REAC~ES
SHELL : .

300gr 1. No No No Pass 5 300gr 2. No No No Pass .
400gr 3. No No No Pass 400gr 4. No - No No Pass .
600gr 5. No S* No Pass 600gr 6. No - S* No Pass S* Smoldering continued for 55 minutes which is close to the limit for the test.

Maximum Smoke Obscuration %:

BY 5 MIN ~Y 10 MIN BY 15 MIN

300 gm.fireload 21% 40% 40%

15 300 gm.fireload 18% 38% 40~

400 gm.fireload 14% 40% 45%

400 gm.fireload 10~ 40% 45%

600 gm.fireload 12% 45~ 60%

600 gm.fireload 15% 56% 65%

Note in all tests the fire was con ined to the immediate area of the ignition source.
The level o smoke when compared to e.g. a fire retardant polyurethane foam seat cushion is considerably lower.

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' WO91/08B86 ~ 7 S` ~' PCT/AU90/00585 2069~7~ ~

Fire Test Performed on F.R. Foam Seat , Max. Smoke Obscuration % BY 5 MIN BY 10 MIN BY 15 MIN

300 gm. fireload 30% 92~ 92%

in tests performed on samples made according to the invention. The time from ignition to maximum level of smoke is extended and the overall level of smoke produced is much lower, allowing a longer period for escape or opportuni~y to put out the fire.
It is thus apparent that the present invention provides an improved and time-saving method of manufacturing vandal resistant seating.

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Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A method of manufacturing a formed (vandal resistant) article including an outer fabric material and an inner micro-cellular thermosetting foam plastics material, comprising :
placing the outer fabric material, which has been treated on its inner side with a flexible thermosetting plastics material composition, in a mould;
closing the mould to define a mould cavity and to deform the fabric material to a predetermined configuration;
injecting a foamable flexible thermosetting plastics material composition into said mould;
allowing the foamable flexible plastics material to react and completely fill said mould, the pressure of the reaction in the closed space of the mould causing the flexible plastics material to bond to the fabric material;
allowing the resultant fabric covered micro-cellular foam plastics material to cure;
opening the mould and removing the article.

2. A method as claimed in Claim 1, in which the volume of unexpanded foamable material injected into the mould cavity is from 50% to 100% of the volume of the cavity.

3. A method as claimed in Claim 1, in which the volume of unexpanded foamable material injected into the mould cavity is from 60% to 99% of the volume of the cavity.

4. A method as claimed in Claim 1, in which the volume of unexpanded foamable material injected into the mould cavity is from 75% to 95% of the volume of the cavity.

5. A method of manufacturing a formed wire mesh reinforced article including an outer fabric material and an inner micro-cellular foam thermosetting comprising plastics material reinforced by a metal wire mesh embedded therein comprising placing the outer fabric material, treated on its inner side with a flexible thermosetting plastics material composition in a mould;
closing the mould to deform the fabric material to a predetermined configuration;
opening the mould and inserting the wire mesh on the inner side of the fabric;
closing the mould and injecting a foamable flexible thermosetting plastics material composition;
allowing the foamable flexible plastics material to react and completely fill the mould, the pressure of the reaction in the closed space of the mould causing the flexible plastics material to surround the wire mesh and to bond to the fabric material;
allowing the resultant fabric covered reinforced.
micro-cellular foam plastics material to cure;
opening the mould and removing the article.

6. A method as claimed in Claim 5, in which the volume of unexpanded foamable material injected into the mould cavity is from 50% to 100% of the volume of the cavity.

7. A method as claimed in Claim 5, in which the volume of unexpanded foamable material injected into the mould cavity is from 60% to 99% of the volume of the cavity.

8. A method as claimed in Claim 5, in which the volume of unexpanded foamable material injected into the mould cavity is from 75% to 95% of the volume of the cavity.

9. A method of manufacturing a formed article comprising :
placing a preform having an outer fabric material, treated on its inner side with a flexible thermosetting plastics material composition, in a mould;
injecting a foamable flexible thermosetting plastics material composition into said mould;
allowing the foamable flexible plastics material to react and completely fill said mould, the process of the reaction in the closed space of the mould causing the flexible plastics material to bond to the fabric material;
allowing the resultant fabric covered micro-cellular foam plastics material to cure;
opening the mould and removing the article.

10. A method as claimed in Claim 9, which includes insertion of a wire reinforcing mesh into the mould on the inner side of the outer fabric material prior to injection of the foamable flexible thermosetting plastics material.

11. A method as claimed in Claim 9 or 10, in which the volume of unexpanded foamable material injected into the mould cavity is from 50% to 100% of the volume of the cavity.

12. A method as claimed in Claim 9 or 10, in which the volume of unexpanded foamable material injected into the mould cavity is from 60% to 99% of the volume of the cavity.

13. A method as claimed in Claim 9 or 10, in which the volume of unexpanded foamable material injected into the mould cavity is from 75% to 95% of the volume of the cavity.

14. A method as claimed in Claim 1, in which the mould includes a vent to permit air to escape from the mould cavity as it is displaced due to the injection of the foamable flexible thermosetting plastics material.

15. A method as claimed in Claim 14, wherein the foamable flexible thermosetting plastics material is injected into the mould at the top of the mould and the vent is at the bottom of the mould.

16. A method as claimed in Claim 5, in which the mould includes a vent to permit air to escape from the mould cavity as it is displaced due to the injection of the foamable flexible thermosetting plastics material.

17. A method as claimed in Claim 16, wherein the foamable flexible thermosetting plastics material is injected into the mould at the top of the mould and the vent is at the bottom of the mould.

18. A method as claimed in Claim 10 or 11, in which the mould includes a vent to permit air to escape from the mould cavity as it is displaced due to the injection of the foamable flexible thermosetting plastics material.

19. A method as claimed in Claim 10 or 11, wherein the foamable flexible thermosetting plastics material is injected into the mould at the top of the mould and the vent is at the bottom of the mould.